Spatial light modulators with light absorbing areas

ABSTRACT

A projection system, a spatial light modulator, and a method for forming micromirrors are disclosed. A substrate comprises circuitry and electrodes for electrostatically deflecting micromirror elements that are disposed within an array of such elements forming the spatial light modulator. In one embodiment, the substrate is a silicon substrate having circuitry and electrodes thereon for electrostatically actuating adjacent micromirror elements, and the substrate is fully or selectively covered with a light absorbing material.

TECHNICAL FIELD OF THE INVENTION

The invention is related generally to spatial light modulators, and,more particularly, to spatial light modulators with light absorbingareas that reduce light reflectance from a substrate having circuitryand electrodes thereon that electrostatically deflect micromirrors in anarray.

BACKGROUND OF THE INVENTION

Spatial Light Modulators (SLMs) are transducers that modulate anincident beam of light in a spatial pattern that corresponds to anoptical or electrical input. A type of SLM is the SLM based on MicroElectro-Mechanical Systems (MEMS). A typical MEMS-based SLM consists ofan array of micro-mirrors mounted on movable elements. Each individualmicro-mirror can be independently deflected by an electrostatic force.Reflection of a beam of incident light impinging a micro-mirror can thenbe controlled, for example by deflecting the micro-mirror throughchanging the electrostatic force applied to the micro-mirror. MEMS-basedSLMs have experienced significant developments and been innovativelyimplemented in many applications, one of which is the use in digitaldisplay systems. In a display application, each micro-mirror isassociated with a pixel of a displayed image. To produce a bright pixel,the state of the micro-mirror associated with the pixel is set in such away that the reflected light from the micro-mirror is directed onto atarget for viewing. And to produce a dark pixel, the status of themicro-mirror is tuned such that the reflected light from themicro-mirror is directed away from the display device. In order todisplay a black-and-white image, the micro-mirror array is illuminatedby a beam of light. By coordinating the reflective status of themicro-mirrors based on the brightness of the pixels of the desiredimage, the collective effect of all reflected lights from individualmicro-mirrors is the generation of the desired image. Gray-scaled andcolored-images can also be displayed using the micro-mirror array withthe pulse-width-modulation and sequential-color-display techniques,which will not be discussed in detail herein.

Currently, varieties of MEMS-based SLMs have been developed. Regardlessof the differences, the function of the MEMS-based SLMs for display isbased on the reflection of light from individual micro-mirrors.Therefore, the quality of the displayed image strongly depends on thereflections of the micro-mirrors.

There are many things that define the quality of a displayed image.Contrast ratio is a major determinant of perceived image quality.Contrast ratio is the ratio of luminance between the brightest whitethat can be produced and the darkest black that can be produced. If adisplayed image has high contrast ratio, a viewer will judge it to besharper than a displayed image with lower contrast ratio, even if thelower contrast image has substantially more measurable resolution.Contrast ratio of a displayed image from a MEMS-based SLM can beseriously degraded by light scattered, for example, from the edges ofthe micro-mirrors and the structures below the micro-mirrors. Thisscattered light typically travels through the projection lens of thedisplay device and is directed on to the target, even when themicro-mirrors are set for displaying a dark pixel.

Therefore, methods for use in MEMS-based SLMs are needed to improve thedisplay quality.

SUMMARY OF THE INVENTION

In view of the forgoing, the present invention provides a spatial lightmodulator with light absorbing areas for improving display quality.

In an embodiment of the invention, a method is provided for making aspatial light modulator. The method comprises: forming an array ofcircuitry and electrodes on a first substrate; forming a light absorbinglayer on the first substrate to reduce reflections from the circuitryand/or electrodes on the substrate; forming an array of deflectablereflective elements on the first substrate or on a second substrate;wherein the light absorbing layer is formed of a material that absorbsat least 50% of the light incident thereon and has a resistivity of from2.5e12 ohm-cm to 1e15 ohm-cm.

In another embodiment of the invention, a spatial light modulator isprovided that comprises: an array of circuitry and electrodes on a firstsubstrate; a light absorbing layer on the first substrate to reducereflections from the circuitry and/or electrodes on the first substrate;an array of micromirrors on the first substrate or on a secondsubstrate; and wherein the light absorbing layer is formed of a materialthat absorbs at least 50% of the light incident thereon and has aresistivity of from 2.5e12 ohm-cm to 1e15 ohm-cm.

In yet another embodiment of the invention, method for making a spatiallight modulator is disclosed. The method comprises: providing a firstsubstrate; forming an array of circuitry and electrodes on the firstsubstrate; forming a light absorbing layer on the first substrate from amaterial that absorbs at least 50% of the light incident thereon and hasa resistivity of from 2.5e12 ohm-cm to 1e15 ohm-cm; forming an array ofdeflectable reflective elements on the first or on a second substrate;and if on the second substrate, bonding the first and second substratestogether to form a substrate assembly.

In yet another embodiment of the invention, a method for making aspatial light modulator is provided. The method comprises: providing afirst substrate and a second substrate; forming a plurality ofelectrodes each of which is associated with a circuitry of an array ofcircuitry on the second substrate; depositing a discrete light absorbingarea on each of the electrodes to form coated electrodes; forming aplurality of deflectable reflective elements on the first or secondsubstrate; and disposing the first and second substrates such that eachdeflectable reflective element is positioned proximate to a coatedelectrode such that the deflectable reflective element is capable ofbeing electrostatically actuated by the coated electrode.

In still another embodiment of the invention, a method is provided formaking a spatial light modulator. The method comprises: providing asubstrate; forming a plurality of electrodes each being associated witha circuitry of a plurality of circuitry on the substrate; depositing adiscrete light absorbing area on each of the electrodes to form coatedelectrodes; and forming a plurality of deflectable reflective elementspositioned above the coated electrodes.

In yet another embodiment of the invention, a method is disclosed formaking a spatial light modulator. The method comprises: providing afirst substrate and a second substrate; forming a plurality ofelectrodes each being associated with a circuitry of a plurality ofcircuitry on the second substrate; depositing light absorbing materialto surround the electrodes such that the light absorbing materialpartially covers the second substrate; forming a plurality ofdeflectable reflective elements on the first substrate; and disposingthe first and second substrates such that each deflectable reflectiveelement is positioned proximate to an electrode such that thedeflectable reflective element is capable of being electrostaticallyactuated by the electrode.

In yet another embodiment of the invention, a method is provided formaking a spatial light modulator. The method comprises: providing asubstrate; forming a plurality of electrodes each with associatedcircuitry on the substrate; depositing light absorbing material tosurround the electrodes such that the light absorbing material partiallycovers the substrate; and forming a plurality of deflectable reflectiveelements positioned above the coated electrodes.

In yet another embodiment of the invention, a method for making aspatial light modulator is disclosed. The method comprises: providing asubstrate; forming a plurality of circuitry and electrodes on thesubstrate; depositing and patterning a photoresist on the substrate soas to provide areas with and without the photoresist on the substrate;depositing a light absorbing material so as to fill the areas withoutphotoresist with the light absorbing material; and removing thephotoresist so as to leave selected areas on the substrate with lightabsorbing material.

In yet another embodiment of the invention, a method for making aspatial light modulator is provided. The method comprising: forming anarray of circuitry and electrodes on a first substrate; forming a lightabsorbing layer on the first substrate to reduce reflections from thecircuitry and/or electrodes on the substrate; forming an array ofdeflectable reflective elements on the first substrate or on a secondsubstrate; and wherein the light absorbing layer is formed of a thinfilm ceramic, wherein the thin film ceramic is deposited by chemicalvapor deposition or physical vapor deposition.

In another embodiment of the invention, a projection system is provided.The projection system comprises: a light source; a spatial lightmodulator for reflecting a beam of light from the light source; aplurality of projection optics for projecting light reflected off of thespatial light modulator onto a target; wherein the spatial lightmodulator is formed by a method of any methods provided above.

BRIEF DESCRIPTION OF THE DRAWINGS

While the appended claims set forth the features of the presentinvention with particularity, the invention, together with its objectsand advantages, may be best understood from the following detaileddescription taken in conjunction with the accompanying drawings ofwhich:

FIGS. 1A to 1E are cross-sectional views illustrating one method forforming micro-mirrors;

FIG. 2 is a top view of a micro-mirror showing line 1—1 for thecross-sectional views in FIGS. 1A to 1E;

FIGS. 3A to 3E are cross-sectional views illustrating the same method asin FIGS. 1A to 1E but along a different cross-section;

FIG. 4 is a top view of a mirror showing line 2—2 for the cross-sectionof FIGS. 3A to 3E;

FIG. 5 is an isometric view of the assembly of two substrates, one withmicro-mirrors, the other with circuitry and electrodes;

FIG. 6 is a cross-sectional view of the assembled device in use;

FIG. 7 is a flow chart of one method of the invention;

FIG. 8 is a top view of a wafer substrate having multiple die areas;

FIGS. 9A to 9E are step-by-step views of the assembly of the device;

FIGS. 10A and 10B are top views of two wafers that will be joinedtogether and then singularized;

FIGS. 10C and 10D are views of light transmissive substrates (FIG. 10A)for bonding to a wafer (10D);

FIG. 11A is a cross-sectional view taken along line 11—11 of FIG. 10upon alignment of the two wafers of FIGS. 10A and 10B, but prior tobonding;

FIG. 11B is a cross-sectional view taken along line 11—11 of FIG. 10upon alignment of the two wafers of FIGS. 10A and 10B after bonding thetwo wafers, but prior to singulation;

FIG. 12 is an isometric view of a singularized wafer assembly die heldon a package substrate;

FIG. 13 is an illustration of a projection system having a micro-mirrordevice therein;

FIG. 14A is an illustration of a light absorbing matrix layer on thelight transmissive substrate;

FIG. 14B is an illustration of another embodiment of a light absorbingmatrix layer on the light transmissive substrate;

FIG. 15 is an illustration of light absorbing die frames on a lighttransmissive substrate;

FIGS. 16A to 16F are illustrations of light absorbing edges formed alongmicro-mirror elements;

FIG. 17 is an illustration of a light absorbing grid or matrix on alight transmissive substrate with micro-mirrors on an adjacent circuitsubstrate; and

FIGS. 18A and 18B are illustrations of light absorbing areas formed onthe wafer with circuitry thereon, wherein FIG. 18A demonstratesabsorbing areas formed on the electrodes; and wherein FIG. 18Bdemonstrates absorbing areas between adjacent electrodes.

DETAILED DESCRIPTION OF THE INVENTION

Mirror Fabrication:

Processes for fabricating a MEMS device such as a movable micro-mirrorand mirror array are disclosed in U.S. Pat. Nos. 5,835,256 and 6,046,840both to Huibers, the subject matter of each being incorporated herein byreference. A similar process for forming MEMS movable elements (e.g.mirrors) on a wafer substrate (e.g. a light transmissive substrate or asubstrate comprising CMOS or other circuitry) is illustrated in FIGS. 1to 4. By “light transmissive”, it is meant that the material will betransmissive to light at least in operation of the device (The materialcould temporarily have a light absorbing layer on it to improve theability to handle the substrate during manufacture, or a partial lightabsorbing layer for decreasing light scatter during use. Regardless, aportion of the substrate, for visible light applications, is preferablytransmissive to visible light during use so that light can pass into thedevice, be reflected by the mirrors, and pass back out of the device. Ofcourse, not all embodiments will use a light transmissive substrate). By“wafer” it is meant any substrate on which multiple micro-mirrors ormicrostructure arrays are to be formed, which allows for being dividedinto dies, each die having one or more micro-mirrors thereon. Though notin every situation, often each die is one device or product to bepackaged and sold separately. Forming multiple “products” or dies on alarger substrate or wafer allows for lower and faster manufacturingcosts as compared to forming each die separately. Of course the waferscan be any size or shape, though it is preferred that the wafers be theconventional rounds or substantially round wafers (e.g. 4″, 6″ or 12″ indiameter) so as to allow for manufacture in a standard foundry.

FIGS. 1A to 1E show a manufacturing process for a micro-mirrorstructure. As can be seen in FIG. 1A, a substrate such as glass (e.g.1737F), quartz, Pyrex™, sapphire, (or silicon alone or with circuitrythereon) etc. is provided. The cross-section of FIGS. 1A-E is takenalong line 1—1 of FIG. 2. Because this cross-section is taken along thehinge of the movable element, an optional block layer 12 can be providedto block light (incident through the light transmissive substrate duringuse) from reflecting off the hinge (or other underlying structure) andpotentially causing diffraction and lowering the contrast ratio (if thesubstrate is transparent). This light-absorbing layer will be describedin more detail in FIG. 14 to FIG. 17.

As shown in FIG. 1B, a sacrificial layer 14, such as amorphous silicon,is deposited. The thickness of the sacrificial layer can be wide rangingdepending upon the movable element/mirror size and desired tilt angle,though a thickness of from 500 Å to 50,000 Å, preferably around 5000 Åis preferred. Alternatively, the sacrificial layer could be a polymer orpolyimide (or even polysilicon, silicon nitride, silicon dioxide, etc.depending upon the materials selected to be resistant to the etchant,and the etchant selected). A lithography step followed by a sacrificiallayer etch form holes 16 a and 16 b in the sacrificial silicon, whichcan be of any suitable size, though preferably having a diameter of from0.1 to 1.5 um, preferably around 0.7±0.25 um. The etching is performeddown to the glass/quartz substrate or down to the block layer ifpresent. Preferably if the glass/quartz layer is etched, it is in anamount less than 2000 Å.

At this point, as shown in FIG. 1C, a first layer 18 is deposited bychemical vapor deposition. The material can be any suitable material,for example silicon nitride or silicon oxide deposited by LPCVD orPECVD—however polysilicon, silicon carbide (or other ceramic thin film)or an organic compound could be deposited at this point—or Al, CoSiNx,TiSiNx, TaSiNx and other ternary and higher order compounds as set forthin U.S. patent application Ser. Nos. 09/910,537 filed Jul. 20, 2001, and60/300,533 filed Jun. 22, 2001 both to Reid and incorporated herein byreference (of course the sacrificial layer and etchant should be adaptedto the material used). Also, multilayer structures having variouscombinations of metals (or metal alloys) and ceramic films could bedeposited. The thickness of this first layer can vary depending upon themovable element size and desired amount of stiffness of the element.However in one embodiment the layer has a thickness of from 100 to 3200Å, more preferably around 1100 Å. The first layer undergoes lithographyand etching so as to form gaps between adjacent movable elements on theorder of from 0.1 to 25 um, preferably around 1 to 2 um.

A second layer 20 (the “hinge” layer) is deposited as shown in FIG. 1D.By “hinge layer” it is meant the layer that defines that portion of thedevice that flexes to allow movement of the device. The hinge layer canbe disposed only for defining the hinge, or for defining the hinge andother areas such as the mirror. In any case, the reinforcing material isremoved prior to depositing the hinge material. The material for thesecond (hinge) layer can be the same (e.g. silicon nitride) as the firstlayer or different (e.g. any suitable material such as silicon oxide,silicon carbide, polysilicon, or Al, CoSiNx, TiSiNx, TaSiNx or otherternary and higher compounds) and can be deposited by chemical vapordeposition like the first layer. The thickness of the second/hinge layercan be greater or less than the first, depending upon the stiffness ofthe movable element, the flexibility of the hinge desired, the materialused, etc. In one embodiment the second layer has a thickness of from 50Å to 2100 Å, preferably around 500 Å. In another embodiment, the firstlayer is deposited by PECVD and the second layer by LPCVD.

As also shown in FIG. 1D, a reflective and conductive layer 22 isdeposited. The reflective/conductive material can be gold, aluminum orother metal, or an alloy of more than one metal though it is preferablyaluminum deposited by PVD. The thickness of the metal layer can be from50 to 2000 Å, preferably around 500 Å. It is also possible to depositseparate reflective and conductive layers. An optional metal passivationlayer (not shown) can be added, e.g. a 10 to 1100 Å silicon oxide layerdeposited by PECVD. Then, photoresist patterning on the metal layer isfollowed by etching through the metal layer with a suitable metaletchant. In the case of an aluminum layer, a chlorine (or bromine)chemistry can be used (e.g. a plasma/RIE etch with Cl₂ and/or BCl₃ (orCl2, CCl4, Br2, CBr₄, etc.) with an optional preferably inert diluentsuch as Ar and/or He)., The sacrificial layer is then removed in orderto “release” the micro-mirror structures (FIG. 1E).

In the embodiment illustrated in FIGS. 1A to 1E, both the first andsecond layers are deposited in the area defining the movable (mirror)element, whereas the second layer, in the absence of the first layer, isdeposited in the area of the hinge. It is also possible to use more thantwo layers to produce a multilayer movable element, which can bedesirable particularly when the size of the movable element is increasedsuch as for switching light beams in an optical switch. A plurality oflayers could be provided in place of a single layer 18 in FIG. 1C, and aplurality of layers could be provided in place of layer 20 and in placeof layer 22. Or, layers 20 and 22 could be a single layer, e.g. a puremetal layer or a metal alloy layer or a layer that is a mixture of e.g.a dielectric or semiconductor and a metal. Some materials for such layeror layers that could comprise of metal alloys and dielectrics orcompounds of metals and nitrogen, oxygen or carbon (particularly thetransition metals) are disclosed in U.S. provisional patent application60/228,007, the subject matter of which is incorporated herein byreference.

In one embodiment, the reinforcing layer is removed in the area of thehinge, followed by depositing the hinge layer and patterning bothreinforcing and hinge layer together. This joint patterning of thereinforcing layer and hinge layer can be done with the same etchant(e.g. if the two layers are of the same material) or consecutively withdifferent etchants. The reinforcing and hinge layers can be etched witha chlorine chemistry or a fluorine (or other halide) chemistry (e.g. aplasma/RIE etch with F₂, CF₄, CHF₃, C₃F₈, CH₂F₂, C₂F₆, SF₆, etc. or morelikely combinations of the above or with additional gases, such asCF₄/H₂, SF₆/Cl₂, or gases using more than one etching species such asCF₂Cl₂, all possibly with one or more optional inert diluents). Ofcourse, if different materials are used for the reinforcing layer andthe hinge layer, then a different etchant can be employed for etchingeach layer. Alternatively, the reflective layer can be deposited beforethe first (reinforcing) and/or second (hinge) layer. Whether depositedprior to the hinge material or prior to both the hinge material and thereinforcing material, it is preferable that the metal be patterned (e.g.removed in the hinge area) prior to depositing and patterning the hingematerial.

FIGS. 3A to 3E illustrate the same process taken along a differentcross-section (cross-section 2—2 in FIG. 4) and show the optional blocklayer 12 deposited on the light transmissive substrate 10, followed bythe sacrificial layer 14, layers 18, 20 and the metal layer 22. Thecross-sections in FIGS. 1A to 1E and 3A to 3E are taken alongsubstantially square mirrors in FIGS. 2 and 4 respectively. However, themirrors need not be square but can have other shapes that may decreasediffraction and increase the contrast ratio. Such mirrors are disclosedin U.S. provisional patent application 60/229,246 to Ilkov et al., thesubject matter of which is incorporated herein by reference. The lightabsorbing material on the light transmissive substrate, as will bediscussed below, can be made to conform to the shape of themirrors—whether the mirrors are formed on the light transmissivesubstrate or on a semiconductor substrate having circuitry, electrodesand micro-mirrors thereon. Also, the mirror hinges can be torsion hingesas illustrated in this provisional application.

It should also be noted that materials and method mentioned above areexamples only, as many other method and materials could be used. Forexample, the Sandia SUMMiT process (using polysilicon for structurallayers) or the Cronos MUMPS process (also polysilicon for structurallayers) could be used in the present invention. Also, a MOSIS process(AMI ABN—1.5 um CMOS process) could be adapted for the presentinvention, as could a MUSiC process (using polycrystalline SiC for thestructural layers) as disclosed, for example, in Mehregany et al., ThinSolid Films, v. 355-356, pp. 518-524, 1999. Any suitable deposition andpatterning methods can be used, depending upon the structure desired tobe deposited. Also, the sacrificial layer and release etchant disclosedherein are exemplary only. For example, a silicon dioxide sacrificiallayer could be used and removed with HF (or HF/HCl), or a siliconsacrificial could be removed with ClF3 or BrF3. Also a PSG sacrificiallayer could be removed with buffered HF, or an organic sacrificial suchas polyimide could be removed in a dry plasma oxygen release step. Ofcourse the release etchant and sacrificial material should be selecteddepending upon the structural material to be used. Also, though PVD andCVD are referred to above, other thin film deposition methods could beused for depositing the layers, including spin-on, sputtering,anodization, oxidation, electroplating and evaporation.

After forming the micro-mirrors as in FIGS. 1 to 4 on the first wafer,it is preferable to remove the sacrificial layer so as to release themicro-mirrors. This release can be performed at the die level, though itis preferred to perform the release at the wafer level. FIGS. 1E and 3Eshow the micro-mirrors in their released state. As can be seen in FIG.1E, posts 24 hold the released microstructure on substrate 10.

Also, though the hinge of each mirror can be formed in the same plane asthe mirror element (and/or formed as part of the same deposition step)as set forth above, they can also be formed separated from and parallelto the mirror element in a different plane and as part of a separateprocessing step. This superimposed type of hinge is disclosed in FIGS.11 and 12 of the previously-mentioned U.S. Pat. No. 6,046,840, and inmore detail in U.S. patent application Ser. No. 09/631,536 to Huibers etal. filed Aug. 3, 2000, the subject matter of which being incorporatedherein by reference. Whether formed with one sacrificial layer as in thefigures, or two (or more) sacrificial layers as for the superimposedhinge, such sacrificial layers are removed as will be discussed below,with a preferably isotropic etchant. This “release” of the mirrors canbe performed immediately following the above described steps, or aftershipment from the foundry at the place of assembly.

In one embodiment the resolution is XGA, 1024×768 pixels, though otherresolutions are possible. A pixel pitch of from 5 to 24 um is preferred(e.g. 14 um).

Backplane:

The second or “lower” substrate (the backplane) die contains a largearray of electrodes on the top metal layer of the die. Each electrodeelectrostatically controls one pixel (one micro-mirror on the upperoptically transmissive substrate) of the microdisplay. The voltage oneach electrode on the surface of the backplane determines whether itscorresponding microdisplay pixel is optically ‘on’ or ‘off,’ forming avisible image on the microdisplay. Details of the backplane and methodsfor producing a pulse-width-modulated grayscale or color image aredisclosed in U.S. patent application Ser. No. 09/564,069 to Richards,the subject matter of which is incorporated herein by reference. Ofcourse a wide variety of methods for causing actuation of themicro-mirrors are available.

In a preferred embodiment, the display pixels themselves are preferablybinary, always either fully ‘on’ or fully ‘off,’ and so the backplanedesign is purely digital. The number of reflective elements (displaypixels) in each die can be any number, such as from 6,000 to about 6million, depending upon the desired resolution of the display. Thoughthe micro-mirrors could be operated in analog mode, no analog capabilityis necessary. For ease of system design, the backplane's I/O and controllogic preferably run at a voltage compatible with standard logic levels,e.g. 5V or 3.3V. To maximize the voltage available to drive the pixels,the backplane's array circuitry may run from a separate supply,preferably at a higher voltage.

One embodiment of the backplane can be fabricated in a foundry 5V logicprocess. The mirror electrodes can run at 0-5V or as high above 5V asreliability allows. The backplane could also be fabricated in ahigher-voltage process such as a foundry Flash memory process using thatprocess's high-voltage devices. The backplane could also be constructedin a high-voltage process with larger-geometry transistors capable ofoperating at 12V or more. A higher voltage backplane can produce anelectrode voltage swing significantly higher than the 5-7V that thelower voltage backplane provides, and thus actuate the pixels morerobustly.

In digital mode, it is possible to set each electrode to either state(on/off), and have that state persist until the state of the electrodeis changed. A RAM-like structure, with one bit per pixel is anarchitecture that can accomplish this. One example is an SRAM-basedpixel cell. Alternate well-known storage elements such as latches orDRAM (pass transistor plus capacitor) are also possible. If a dynamicstorage element (e.g. a DRAM-like cell) is used, it is desirable that itbe shielded from incident light that might otherwise cause leakage.

A grayscale or full-color image can be produced by modulating pixelsrapidly on and off, for example according to the method in theabove-mentioned U.S. patent application Ser. No. 09/564,069 to Richardsor other suitable methods. In order to support this, it is preferablethat the backplane allows the array to be written in random-accessfashion, though finer granularity than a row-at-a-time is generally notnecessary.

It is desirable to minimize power consumption, primarily for thermalreasons. Decreasing electrical power dissipation will increase theoptical/thermal power budget, allowing the microdisplay to tolerate theheat of more powerful lamps. Also, depending upon the way themicrodisplay is assembled (wafer-to-wafer join+offset saw), it may bepreferable for all I/O pads to be on one side of the die. To minimizethe cost of the finished device it is desirable to minimize pin count.For example, multiplexing row addresses or other infrequently-usedcontrol signals onto the data bus can eliminate separate pins for thesefunctions with negligible throughput penalties (a few percent, e.g. oneclock cycle for address information per row of data is acceptable). Adata bus, a clock, and a small number of control signals (5 or less) areall that is necessary.

In use, the die can be illuminated with a 200W or more arc lamp. Thethermal and photo-carrier effects of this may result in special layoutefforts to make the metal layers as ‘opaque’ as possible over the activecircuitry to reflect incident optical energy and minimize photocarrierand thermal effects. Also, some light can get between the mirrors or hitthe mirror edges, and then scatter from one or more surfaces and end upentering the projection lens/collection optics when the dark state isdesired. This has the negative effect of reducing contrast.

To eliminate this scattered light non-reflective material can be placedon the backplane as a final layer. The non-reflective material can be adark, opaque (e.g. black, grey or other dark color) thin film. Examplesof materials that can be placed on backplane to absorb scattered lightinclude a non-conductive blanket film such as polyimide with carbonparticles (e.g. DARC(™) from Brewer Science). Or other dark coloredceramic films such as CrNx, CrOx, TiAlN, TaNx or other films comprisingof carbon, such as amorphous CN, amorphous CAlN, TiCN, a-DLC, SiC,TiAlCN, WC, etc.—preferably a non-conductive film can be used. In thealternative, conductive dark films could be used that are placeddirectly over the electrodes on the backplane and are electricallyconnected to the electrodes. Such a film could be a dark metal or metalalloy such as sputtered black chrome or niobium that has a reflectanceas low as 3%. The black chrome coating can be a multilayer structure ofchrome and chromium oxide (to match the index of refraction, as in anantireflective coating multilayer film). Of course, other opaque films(preferably those with high optical density, thermally stable and withlow reflectivity) can be deposited and patterned (the opacity and colorof many films being variable due to deposition parameters). Lightabsorbing conductive materials that can be deposited on the electrodesinclude black nickel, and films comprising carbon, such as a-DLC orvitreous carbon. It is also possible to deposit a dark electricallyconductive grid or matrix surrounding all of the electrodes (withoutelectrically connecting the electrodes).

It is also possible to put an “anti-reflective coating” (an AR film) onthe backplane. For example a normally absorptive surface can haveenhanced absorption if an “AR film” stack (for example lighttransmissive dielectric layers), are placed above it so that lightreflection is reduced due to destructive interference. Such dielectricslayers can be designed to work particularly well at certain wavelengthsand/or angles—and can be used for the matrix or frame on the lighttransmissive substrate, as will be discussed below.

Assembly

After the upper and lower substrates (wafers) are finished beingprocessed (e.g. circuitry/electrodes on lower wafer, micro-mirrors onupper wafer), the upper and lower wafers are joined together. Thisjoining of the two substrates allows micro-mirrors on one substrate tobe positioned proximate to electrodes on the other substrate. Thisarrangement is illustrated in FIGS. 5 and 6, which will be describedfurther below.

The method for the assembly of the wafers and separation of the waferassembly into individual dies is similar to the method for assembly ofliquid crystal devices as disclosed in U.S. Pat. No. 5,963,289 toStefanov et al, “Asymmetrical Scribe and Separation Method ofManufacturing Liquid Crystal Devices on Silicon Wafers”, which is herebyincorporated by reference. Many bonding methods are possible such asadhesive bonding (e.g. epoxy, silicone, low K material or otheradhesive—described further herein), anodic bonding, compression bonding(e.g. with gold or indium) metal eutectic bonding, solder bonding,fusion bonding, or other wafer bonding processes known in the art.Whether the upper and lower wafer are made of the same or differentmaterials (silicon, glass, dielectric, multilayer wafer, etc.), they canfirst be inspected (step 30 in the flow chart of FIG. 7) for visualdefects, scratches, particles, etc. After inspection, the wafers can beprocessed through industry standard cleaning processes (step 32 in theflow chart of FIG. 7). These include scrubbing, brushing or ultrasoniccleaning in a solvent, surfactant solution, and/or de-ionized (DI)water.

The mirrors are preferably released at this point (step 34 in the flowchart of FIG. 7). Releasing immediately prior to the application ofepoxy or bonding is preferable (except for an optional stictiontreatment between release and bonding). For silicon sacrificial layers,the release can be in an atmosphere of xenon difluoride and an optionaldiluent (e.g. nitrogen and/or helium). Of course, other etchants couldbe used, including interhalogens such as bromine trifluoride and brominetrichloride. The release is preferably a spontaneous chemical etch whichdoes not require plasma or other external energy to etch the siliconsacrificial layer(s). Or the release can be performed with asupercritical fluid such as set forth in U.S. patent application Ser.No. 10/167,272 filed Jun. 10, 2002, incorporated herein by reference.After etching, the remainder of the device is treated for stiction (step36 in the flow chart of FIG. 7) by applying an anti-stiction layer (e.g.a self assembled monolayer). The layer is preferably formed by placingthe device in a liquid or gas silane, preferably a halosilane, and mostpreferably a chlorosilane. Of course, many different silanes are knownin the art for their ability to provide anti-stiction for MEMSstructures, including the various trichlorsilanes set forth in “SelfAssembled Monolayers as Anti-Stiction Coatings for MEMS: Characteristicsand Recent Developments”, Maboudian et al., as well as otherunfluorinated (or partially or fully fluorinated) alkyltrichlorosilanes, preferably those with a carbon chain of at least 10carbons, and preferably partially or fully fluorinated.(Tridecafluoro-1,1,2,2-tetrahydro-octyl)trichlorosilane available fromGelest, Inc. is one example. Other trichlorosilanes (preferablyfluorinated) such as those with phenyl or other organic groups having aring structure are also possible.

In order to bond the two wafers together, spacers are mixed into sealantmaterial (step 38 in the flow chart of FIG. 7). Spacers in the form ofspheres or rods are typically dispensed and dispersed between the wafersto provide cell gap uniformity and space for mirror deflection. Spacerscan be dispensed in the gasket area of the display and therefore mixedinto the gasket seal material prior to seal dispensing. This is achievedthrough normal agitated mixing processes. The final target for the gapbetween the upper and lower wafers is preferably from 1 to 10 um, thoughother gaps are possible depending upon factors such as micro-mirror sizeand deflection angle. The spheres or rods can be made of glass orplastic, preferably an elastically deforming material. Alternatively,spacer pillars can be fabricated on at least one of the substrates. Inone embodiment, pillars/spacers are provided only at the side of thearray. In another embodiment, pillars/spacers can be fabricated in thearray itself. Other bonding agents with or without spacers could beused, including anodic bonding or metal compression bonding with apatterned eutectic or metal.

A gasket seal material can then be dispensed (step 40 in the flow chartof FIG. 7) on the bottom substrate in a desired pattern, usually in oneof two industry standard methods including automated controlled liquiddispensing through a syringe and printing (screen, offset, or roller).When using a syringe, it can be moved along X-Y coordinates relative tothe parts. The syringe tip is constrained to be just above the part withthe gasket material forced through the needle by positive pressure.Positive pressure can be provided either by a mechanical plunger forcedby a gear driven configuration and/or by an air piston and/or pressedthrough the use of an auger. Of course many different adhesivedispensing methods can be used.

Then, the two wafers are aligned (step 42 in the flow chart of FIG.7)—preferably to within 1 micron accuracy or less. Alignment of theopposing electrodes or active viewing areas is aided by registration ofsubstrate fiducials on opposite substrates. This task can beaccomplished with the aid of video cameras with lens magnification. Themachines range in complexity from manual to fully automated with patternrecognition capability. Whatever the level of sophistication, theypreferably accomplish the following: (a) Dispense a very small amount ofa UV curable adhesive at locations near the perimeter and off of allfunctional devices in the array; (b) Align the fiducials of the opposingsubstrates within the equipment capability; and (c) Press substrates andUV tack for fixing the wafer-to-wafer alignment through the remainingbonding process (e.g., curing of the internal epoxy).

The final cell gap can be set by pressing (step 44 in the flow chart ofFIG. 7) the previously tacked laminates in a UV or thermal press. In aUV press, a common procedure would have the substrates loaded into apress where at least one or both of the press platens are quartz, inorder to allow UV radiation from a UV lamp to pass unabated to thegasket seal epoxy. Exposure time and flux rates are process parametersdetermined by the equipment and adhesive materials. Thermally curedepoxies require that the top and bottom platens of a thermal press beheated. The force that can be generated between the press platens istypically many pounds. With thermally cured epoxies, after the initialpress the arrays are typically transferred to a stacked press fixturewhere they can continually to be pressed and post-cured for 4-8 hours.

Once the wafers have been bonded together to form a wafer assembly, theassembly can be separated into individual dies (step 46 in the flowchart of FIG. 7). Silicon substrate and glass scribes are placed on therespective substrates in an offset relationship at least along onedirection. Or, the substrates can be provided initially with scribes onthem already. The units are then separated, resulting in each unithaving a bond pad ledge on one side and a glass electrical contact ledgeon an opposite side—if such an offset arrangement is desired. The partsmay be separated from the array by any of the following methods. Theorder in which the array (glass first) substrate is scribed is importantwhen conventional solid-state cameras are used for viewing and alignmentin a scribe machine. This constraint exists unless special infraredviewing cameras are installed which make the silicon transparent andtherefore permits viewing of front surface metal fiducials. The scribetool is aligned with the scribe fiducials and processed. The resultantscribe lines in the glass can be used as reference marks to align thesilicon substrate scribe lanes. These scribe lanes may be coincidentwith the glass substrate scribes or uniformly offset. The parts are thenseparated from the array by venting the scribes on both substrates.Automatic breaking is done by commercially available guillotine orfulcrum breaking machines. The parts can also be separated by hand. Or,any other suitable singularization method can be used to separate thebonded wafers into bonded wafer die portions.

For example, separation may also be done by glass scribing and partialsawing of the silicon substrate. Sawing requires an additional step atgasket dispense. Sawing can be performed in the presence of ahigh-pressure jet of water. Moisture should preferably not be allowed inthe area of the fill port or damage of the MEMS structures could occur.Therefore, at gasket dispense, an additional gasket bead must bedispensed around the perimeter of the wafer. The end of each scribe/sawlane must be initially left open, to let air vent during the align andpress processes. After the array has been pressed and the gasketmaterial cured, the vents are then closed using either the gasket orend-seal material. The glass is then aligned and scribed as describedabove. Sawing of the wafer is done from the backside of the siliconwhere the saw streets are aligned relative to the glass scribe lanesdescribed above. The wafer is then sawed to a depth of 50%-90% of itsthickness. The parts are then separated as described above.

Alternatively, both the glass and silicon substrates may be partiallysawed prior to part separation. With the same gasket seal configuration,vent and seal processes as described above, saw lanes are aligned tofiducials on the glass substrates. The glass is sawed to a depth between50% and 95% of its thickness. The silicon substrate is sawed and theparts separated as described above.

For an illustrated example of the above, reference is made to FIG. 8where 45 die areas have been formed on wafer 5. Each die area 3 (havinga length A and a height B) comprises one or more (preferably released)micro-mirrors. In the case of micro-mirror arrays for projectionsystems, each die preferably has at least 1000 movable mirrors, and morelikely between 1 and 6 million movable elements.

As can be seen in FIG. 9A, four die areas 3 a to 3 d are formed on wafer5 (many more dies would be formed in most circumstances, though onlyfour are shown for ease of illustration). Each die area 3 a to 3 dcomprises one or more micro-mirrors, which have already been released ina suitable etchant. As illustrated in FIG. 9B, epoxy can be applied inthe form of beads 51 a to 51 d along each side of the die area, or asbeads 53 a to 53 d at each corner of the die area. Or, epoxy ribbons 55a and 55 b could be applied along two sides of each die, or a singleribbon 57 could be applied substantially surrounding an entire die. Ofcourse many other configurations are possible, though it is desirablethat the die not be fully surrounded with an epoxy gasket, as this willprevent air or other gas from escaping when the two wafers are pressedtogether during a full or partial epoxy cure. And, of course, it ispreferable, for higher manufacturing throughput, to use a common epoxyapplication method throughout the entire wafer (the different types ofapplications in FIG. 9B are for illustrations purposes only). Also, theareas in which epoxy is applied can first have a sacrificial materialdeposited in that area (preferably in an area larger than the bead orband of epoxy due to expansion of the epoxy under compression). Thesacrificial material could also be applied to the entire wafer except inareas having micro-mirrors thereon. Also, a conductive epoxy (or otheradhesive) could be used in order to make electrical contact between thewafer having circuitry and electrodes and the wafer having MEMS thereon.

In FIG. 9C, upper wafer 25 and the lower substrate wafer 5 withmicro-mirrors (and optionally circuitry) are brought into contact witheach other. The final gap between the two wafers can be any size thatallows the two wafers to be held together and singularized uniformly.Because gasket beads will expand upon application of pressure (thustaking up valuable real estate on a wafer with densely positioned dieareas), it is preferable that the gap size be larger than 1 um, andpreferably greater than 10 um. The gap size can be regulated byproviding microfabricated spacers or spacers mixed in with the epoxy(e.g. 25 um spacers). However, spacers may not be necessary dependingupon the type of microstructure and the amount of pressure applied.

FIG. 9D shows the lower wafer 5 and upper wafer 25 bonded together.Horizontal and vertical score or partial saw lines 21 a and 21 b areprovided on both the upper wafer 25 and the first (lower) wafer 5 (linesnot shown on wafer 5). Preferably the score lines on the two wafers areoffset slightly from each other at least in one of the (horizontal orvertical). This offset scoring or partial sawing allows for ledges oneach die when the wafer is completely singularized into individual dies(see FIG. 9E). Electrical connections 4 on ledge 6 on die 3 c allow forelectrical testing of the die.

Referring again to FIG. 5, a top perspective view of a portion of abonded wafer assembly die 10 is illustrated. Of course, the mirrorshapes illustrated in FIGS. 1 to 5 are exemplary, as many other mirrorstructures are possible, such as set forth in U.S. patent applicationSer. No. 09/732,445 to Ilkov et al. filed Dec. 7, 2000, incorporatedherein by reference. For clarity, only four pixel cells 54, 54 a, 54 band 54 c in a two by two grid configuration are shown in FIG. 5. Thepixel cells 54, 54 a, 54 b and 54 c have a pixel pitch of, for example,12 microns. “Pixel pitch” is defined as the distance between likeportions of neighboring pixel cells.

Reflective deflectable elements (e.g., mirrors 48, 48 a, 48 b and 48 c),each corresponding to a respective pixel cell 54, 54 a, 54 b and 54 c,are attached to the lower surface 14 of the optically transmissivesubstrate 52 in an undeflected position. Thus, mirrors 48, 48 a, 48 band 48 c are visible through optically transmissive substrate 52 in FIG.5. For clarity, light absorbing aperture layers 56 if present, betweenthe mirrors 48, 48 a, 48 b or 48 c and the optically transmissivesubstrate 52, are represented only by dashed lines so as to showunderlying hinges 50, 50 a, 50 b and 50 c. The distance separatingneighboring mirrors may be, for example, 0.5 microns or less.

The optically transmissive substrate 52 is made of materials, which canwithstand subsequent processing temperatures. The optically transmissivesubstrate 52 may be, for example, a 4 inch quartz wafer 500 micronsthick. Such quartz wafers are widely available from, for example, HoyaCorporation U.S.A at 960 Rincon Circle, San Jose, Calif. 95131. Or, thesubstrate can be glass such as Corning 1737 or Corning Eagle2000 orother suitable optically transmissive substrate. In a preferredembodiment, the substrate is transmissive to visible light, and can bedisplay grade glass.

As can be seen in FIG. 6, the light transmissive substrate 52 is bondedto e.g. a MOS-type substrate 62 (a semiconductor substrate can be usedsuch as a silicon substrate with circuitry and electrodes formedthereon) in spaced apart relation due to spacers 66. A plurality ofelectrodes 63 are disposed adjacent a plurality of micro-mirrors 64(mirrors simplified and only 9 illustrated for convenience) forelectrostatically deflecting the micro-mirrors. An incoming light beam65 a will be reflected by a non-deflected mirror at the same angle as itis incident, but will be deflected “vertically” as outgoing light beam65 b when the mirror is deflected. An array of thousands or millions ofmirrors selectively moving and deflecting light “vertically” towardprojection optics, along with a color sequencer (wheel or prism) thatdirects sequential beams of different colors onto the mirrors, resultsin a color image projected on a target (e.g. for projection television,boardroom projectors, etc.). A simplified schematic of one type ofprojection system is illustrated in FIG. 13, where a light source 110,e.g. an arc lamp having a reflector 120, directs light through a colorsequencer (e.g. color wheel 130 that rotates around axis of rotation 170via motor 140), after which the light enters light pipe 150 and optics160 so as to be incident on a micro-mirror array 180 and is reflectedoff of the micro-mirrors of the array and projected via projectionoptics 190 to a target 210.

The method for forming micro-mirrors as set forth above is but oneexample of many methods for forming many different MEMS devices (whetherwith or without an electrical component), in accordance with the presentinvention. Though the electrical component of the final MEMS device isformed on a separate wafer than the micro-mirrors in the above example,it is also possible to form the circuitry and micro-mirrorsmonolithically on the same substrate. The method for forming suchmicro-mirrors could be similar to the methods described herein (with thedifference being that the mirrors are formed on the substrate afterforming circuitry and electrodes). Or, other methods for formingcircuitry and micro-mirrors monolithically on the same substrate asknown in the art could be used.

FIGS. 10A and 10B show two wafers that will be joined together and thensingularized. FIG. 10A is a top view of a light transmissive cover wafer(having a mask area, getter area, lubricant area and compression metalbonding area) whereas FIG. 10B is an illustration of such amonolithically formed mirror array (e.g. for a spatial light modulator)on a bottom semiconductor wafer (along with a metal area for compressionbonding). Referring first to FIG. 10B, a plurality of mirror arrays 71 ato 71 e is formed on a “bottom” wafer 70 (e.g. a silicon wafer). Afterthe mirrors are released, a metal for compression bonding is applied(areas 73 a to 73 e) around each mirror array. Of course more arrayscould be formed on the wafer (as shown in FIG. 8). On a “top” wafer 80(e.g. glass or quartz—preferably display grade glass) are formed masks81 a-e, which will block visible light around a perimeter area of eachdie from reaching the mirror arrays after the two wafers are bonded andsingularized. Also illustrated in FIG. 10A are areas of lubricant 83a-e, areas of getter material 85 a-e, and areas of metal for compressionbonding 87 a-e. If the wafer of FIG. 10B has been treated with a selfassembled monolayer or other lubricant, then the addition of a lubricanton the wafer of FIG. 10A may be omitted if desired (although multipleapplications of lubricants can be provided). The lubricant applied tothe wafer as a gasket, band or drop on the wafer, can be any suitablelubricant, such as the various liquid or solid organic (or hybridorganic-inorganic materials) as known in the art. In one embodiment, atrichlorosilane SAM is applied to the entire wafer or large portions ofthe wafer at least covering the micro-mirror elements, and a silicone isapplied to the lubricant areas 83 a-e. The metal for compression bondingcould be any suitable metal for this purpose such as gold or indium.(Alternatively, if an adhesive is used, the adhesive could be anysuitable adhesive, such as an epoxy or silicone adhesive, and preferablyan adhesive with low outgassing). Of course any combination of theseelements could be present (or none at all if the bonding method is otherthan an adhesive bonding method). Preferably one or more of the mask,lubricant, getter and bonding material are present on the “top” wafer 80prior to bonding. Also, the lubricant, getter and bonding material couldbe applied to only the top or bottom wafer or both wafers. In analternate embodiment, it may be desirable to apply the lubricant andgetter to the bottom wafer around the circuitry and electrodes, withbonding material on both wafers. Of course, depending upon the MEMSapplication, the mask (or the lubricant or getter) may be omitted (e.g.for non-display applications). Also, the bands of lubricant, getter andbonding material need not fully encircle the “die area” on the wafer,but could be applied in strips of dots as illustrated in FIG. 9B. If thebonding material does not fully encircle the MEMS die area, then, priorto singulation, it is preferred that the bonding material “gap” befilled so as to protect the MEMS devices during singulation (fromparticulate and/or liquid damage depending upon the singulation method).

It is also possible to bond multiple substrates (smaller than a singlewafer) to another wafer. In the embodiment illustrated in FIGS. 10C and10D, substrates 101 a to 101 d are substrates transmissive to visiblelight and have thereon masks 81 a to 81 d as well as areas of lubricant83 a to 83 d, areas of getter material 85 a to 85 d, and areas ofbonding material 87 a to 87 d (e.g. gold or indium for metal compressionbonding. The mask areas are preferably “picture frame” shapedrectangular areas that block the transmission of visible light. Thisarrangement is desirable for selectively blocking light incident onmicro-mirror arrays formed on the wafer. By absorbing light in thisarea, light that is incident on the periphery of the micromirror arrayis not reflected or scattered onto the target—but instead is absorbed inthis rectangular peripheral area thus allowing for a sharp rectangularimage on the target. After bonding the multiple substrates with maskareas to the wafer, the wafer is singularized into wafer assemblyportions, followed by packaging such as in FIG. 12.

The MEMS wafers could be made of any suitable material, depending uponthe final application for the devices, including silicon, glass, quartz,alumina, GaAs, etc. Silicon wafers can typically be processed to includecircuitry. For an optical MEMS application (e.g. micro-mirrors foroptical switching or for displays), the “top” wafer of FIG. 10A ispreferably transparent, as mentioned above. The mask illustrated in FIG.10A, can be an absorptive or reflective mask, such as one made from TiN,AlN, or other oxide or nitride compound, or polymers or other suitablematerials having sufficient light absorbing capabilities. This “top”wafer could also incorporate other optical elements, such as lenses, UVor other types of filters or antireflection and/or antiscratch coatings.

Then, the two wafers are aligned, bonded, cured (e.g. with UV light orheat depending upon the type of adhesive used) and singularized as setforth above. FIG. 11A is a cross-section taken along line 11—11 in FIG.10A (after alignment with bottom wafer 70 in FIG. 10B), whereas FIG. 10Bis the same cross-section after bonding (but before singulation). FIG.12 is an illustration of a packaged wafer assembly portion aftersingularization of the bonded wafers. As can be seen in FIG. 12, a lowersubstrate 94 is bonded to the upper substrate 93, with the lowersubstrate held on a lower packaging substrate 90. Metal areas 96 onlower wafer portion 94 will be electrically connected to metal areas 97on the package substrate 90. As can be seen in this Figure, unlike otherMEMS packaging configurations, there is no need to further encapsulateor package the wafer assembly die formed of substrates 93 and 94, as theMEMS elements are already protected within the wafer assembly (though a“second” package surrounding the substrate assembly could be used foradded protection and hermeticity). As such, the die comprised oftwo-bonded die substrates (light transmissive and semiconductor, forexample, with MEMS elements on the light transmissive substrate) seal(preferably hermetically) the MEMS elements from ambient. A micro-mirrorarray comprised of micro-mirrors held on a first substrate (preferablyglass and more preferably display quality glass) which substrate isbonded to a semiconductor substrate (preferably silicon) which in turnis bonded to a lower package substrate that does not fully encapsulatethe bonded die substrates (because the light transmissive andsemiconductor substrates already encapsulate the MEMS elements) is aless expensive alternative to standard packaging of micro-mirror arraysfor projection displays. Also, such a packaging arrangement allows forproviding anti-stiction treatment, getters etc. at the wafer levelfurther decreasing costs of packaging the device. Of course, anadditional package surrounding the substrate assembly could also beused.

Alternatively, it is possible to fully encapsulate the two bonded diesubstrates within a fully surrounding package (having an opticallytransmissive window for light to enter and exit the package). Such afully surrounding package could be a hermetic package with, for example,a pressure less than ambient pressure. The pressure between the bondeddie substrates hermetically sealed together can be less than 1 atm,preferably less than 0.25 atm, and more preferably less than Torr. Ifvery low pressures are desired, then pressures between the substrates ofless than 10 Torr, less than 1 Torr or even as low as 100 mTorr can beused. Getters, lubricants, etc. could be disposed within thissurrounding package rather than within the bonded substrates.

As mentioned above in relation to FIGS. 11A and 11B, on the lighttransmissive wafer 80 (e.g. glass or quartz—preferably display gradeglass) are formed masks 81 a to 81 e which will block visible lightaround a perimeter area of each die from reaching the mirror arraysafter the two wafers are bonded and singularized. This “frame” of lightabsorbing material is preferably one that absorbs many wavelengths inthe visible spectrum. An opaque material, preferably a black material ispreferred for the mask around the perimeter of each die. Such frames or“masks” around each micro-mirror array are shown in FIG. 15. In thisfigure, a light transmissive substrate 102 is provided with lightblocking/absorbing frame areas 100 that surround each die area 101 onthe substrate 102. The material that forms the dark frame area 100 canbe thin film deposited by CVD, PVD etc. and patterned to form the frameareas around each die area on the wafer. In one embodiment ion beamsputtered black chrome or niobium is used, that has a reflectance as lowas 3% through the light transmissive substrate, with high thermalstability. After sputtering the film onto e.g. glass, it is etched toform the “frames” in each die area. The black chrome coating can be amultilayer structure of chrome and chromium oxide (to match the index ofrefraction, as in an antireflective coating multilayer film). Of course,other opaque films (preferably those with high optical density,thermally stable and with low reflectivity) can be deposited andpatterned (the opacity and color of many films being variable due todeposition parameters). Light absorbing materials can be used such asblack nickel, CrN, TiAlN, TaN and many films comprising carbon, such asamorphous CN, amorphous CAlN, TiC, TiCN, a-DLC, vitreous carbon, SiC,TiAlCN, WC, etc. Multilayer structures, such as TiClWC, WC/C orTiAlN/WC/C, can be used, as well as other multilayer structures withmatched indices. Also polyimides and other polymers containing carbonblack (or other opacity increasing material) can be used. If thelight-absorbing layer is exposed to an etchant at the time of release ofthe micro-mirrors, the light absorbing material should preferably beresistant to the etchant used.

Forming the light absorbing areas can be by any suitable film formingmethod—such as standard deposition and patterning techniques. Forexample, the metals and metal alloys can be deposited by sputtering atarget in an inert atmosphere. Other techniques, such as electroplatingcan be used. For ceramic materials, a target can be reactivelysputtered—such as in a nitrogen atmosphere to form nitride ceramicfilms. Or, some films can be deposited by chemical vapor deposition asknown in the art. Patterning of the films to form matrices, bands,strips or other designs can be by any suitable etching chemistry—such asby a chlorine (plasma) etch after deposition and patterning of aphotoresist. It is also possible to deposit and pattern a photoresistfollowed by deposition of the light absorbing material.

As mentioned elsewhere herein, in each die area (101 in FIG. 15) will beformed an array of micro-mirrors—possibly thousands or millions of suchmirrors in each die area—depending upon the desired resolution of theimage reflected from such micro-mirror array. A frame of light absorbingmaterial, such as that disclosed above for surrounding each die area,can be provided on the light transmissive substrate to surround the areawhere each micro-mirror will be formed on the light transmissivesubstrate. Whereas the frame areas surrounding each die (such as in FIG.15) are on the order of millimeters to centimeters in length, the frameareas that surround each micro-mirror are on the order ofmicrons—depending upon the desired size of the micro-mirrors formed—e.g.from 5 to 25 microns. Such “micro-mirror frames” are illustrated inFIGS. 14A and 14B as a light absorbing matrix or grid 98 on a substrate99—where thousands or millions of such frames illustrated in FIGS. 14Aand 14B can be disposed within a single light absorbing frame of FIG.15. If micromirrors are formed on this light transmissive substrate,then it can also be desirable to provide light absorbing material inareas where the micromirrors are held on the light transmissivesubstrate. Or course it is not necessary that both micro-mirror framesof FIG. 14 and die frames of FIG. 15 be provided together. The materialsused to form the micro-mirror frames can be those such as set forthabove in relation to die frames and can include an AR coating (the ARcoating can also cover the entire light transmissive substrate ifdesired.

The “frames” around the micro-mirrors and around the die areas (themicro-mirror array areas) can instead be provided in the form of stripsor bands—where the light blocking or absorbing material is providedalong some but not all sides of the micro-mirrors (or micro-mirrorarrays). Also, though the light absorbing material is preferablyprovided on the same side of the light transmissive substrate as themicro-mirrors, it is also possible to deposit the light absorbingmaterial on the side of the light transmissive substrate opposite fromthe formed micro-mirrors. If the light absorbing material is providedbetween the micro-mirrors and on the same side as the micro-mirrors, itcan be deposited so as to be in the area of impact of the micro-mirrorson the light transmissive substrate. Such impacting of the micro-mirrorson the light transmissive substrate is discussed in detail in U.S. Pat.Nos. 6,356,378, 6,046,840 and 6,172,797 incorporated herein byreference. If the light absorbing strips or frames are disposed at suchimpact point of the micro-mirror, then preferably such material is ahard and at least minimally electrically conductive to allow dissipationof charge that builds up due to repeated impact of the micro-mirrors.

In the above embodiments, the light absorbing areas are provided on thesame substrate as the micro-mirrors. However, it is also possible toform micro-mirrors on a circuit substrate (e.g. a silicon substratehaving thereon circuitry, electrodes and micro-mirrors). In such a case,the light absorbing layers are provided on a separate light transmissivesubstrate that is held spaced apart from the circuit substrate—thoughpreferably at a small distance such as less than 100 microns, preferablyless than 10 microns. It is possible to position the light transmissivesubstrate at a distance of from 1 to 5 microns. A close relationshipbetween the light transmissive substrate and the micro-mirrors can allowfor better blocking of light between adjacent micro-mirrors.

An example of such an arrangement is illustrated in FIG. 17. As can beseen in this Figure, a substrate 122 (e.g. a silicon substrate) withcircuitry and electrodes thereon (not shown) has formed above thecircuitry and electrodes an array of micro-mirrors 129. In the exampleof FIG. 17, for ease of illustration only a few micro-mirrors are shownalong the length of the mirror array—of course an actual mirror arraywould likely have hundreds or thousands of micro-mirrors along onedimension of the array—depending upon the desired resolution of theprojection display. In the example of FIG. 17, each micro-mirror wouldhave two electrodes disposed on the substrate below for tilting themicro-mirror in opposite directions depending upon which electrodecauses electrostatic attraction of the adjacent micro-mirror. Of courseother arrangements, such as micro-mirrors pivotable towards thesubstrate in a single direction, could be used.

Substrate 120 is a light transmissive substrate, such as a plastic,glass or quartz substrate—preferably a display grade glass substrate.Formed on substrate 120 is a frame 123 that surrounds the micro-mirrorarray. Frame 123 in many cases will be a frame disposed as a rectangularthin film—but it is also possible for a material that acts as a spacerto space the substrates 120 and 122 apart, or as a bonding agent, to beopaque and act as the frame surrounding the micro-mirror array. Alsodisposed on substrate 120 are light absorbing areas 126 that aredisposed between the micro-mirrors 129 when the two substrates aredisposed adjacent each other. Though the light absorbing areas 126 canbe in the form of strips or other patterns, it is preferred that thelight absorbing areas are a grid or matrix that allows light to pass inareas where the micro-mirrors are disposed, but blocks light in areascorresponding to gaps between the micro-mirrors. The materials forforming the light absorbing areas 123 and 126 can be as in the otherembodiments hereinabove. Also, substrates 120 and 122 can be bondeddirectly together or indirectly via packaging or other structure.

In a preferred embodiment, the substrates are bonded together at thewafer level by a) bonding e.g. a glass wafer and a silicon wafertogether and then singularizing into dies, or b) bonding glass (or otherlight transmissive material) dies or caps having the light absorbingstrips or grids to a semiconductor (or other circuit containing) waferand then singularizing the semiconductor wafer. It is preferred that thesubstrates 120 and 122 be disposed close to each other (or, if substrate120 is in the form of a concave “cap”, then the area of the cap havingthe matrix be disposed close to substrate 122). Preferably thesubstrates are disposed at a distance of less than 100 microns, and morepreferably less than 50 microns. Or course, closer distances are easilyachieved particularly if the two substrates are bonded together.Substrate distances of 10 microns or less can be achieved, or even 5microns or less if desired.

Though the light transmissive substrate (e.g. a glass or quartz wafer)can be a window in the micro-mirror package, it is also possible to bondthe light transmissive substrate directly to the semiconductor (siliconsubstrate with circuitry) at the die or wafer level—preferably at thedie level. In this way, the light transmissive substrate is bondeddirectly to the semiconductor substrate—allowing a close gap between thetwo substrates. Bonding the two substrates at the wafer level alsoallows for protecting the micro-mirrors during wafer singulation intodies—such as set forth in U.S. patent application Ser. No. 10/005,308 toPatel et al. filed Dec. 03, 2001, incorporated herein by reference.

Another design for reducing scattering of light and increasing thecontrast ratio is by providing a light absorbing layer or strip alongthe edges of the micro-mirrors. The light absorbing material can be thesame as disclosed above with respect to the light absorbing matrices. Ascan better be seen in FIG. 16A, a substrate 111 (this can be a lighttransmissive substrate such as glass, or a semiconductor substrate withactuation circuitry thereon) is provided on which is deposited asacrificial layer 112, which can be of any suitable material such asthose sacrificial materials disclosed elsewhere herein. After depositingsacrificial layer 112, mirror layer 113 is formed. Mirror layer 113 canbe a single layer of a reflective material, such as a metal, metal alloyor metal compound, or a laminate, where preferably one of the layers isreflective. On layer(s) 113 is deposited light absorbing layer 114. Eachof the layers in FIG. 16A can be patterned prior to depositing the nextlayer (or patterned together with adjacent layers, depending upon thematerial of the adjacent layers). And, it should be noted that FIGS. 16Aand 16B are simplified views—additional layers such as hinge layersabove or below the mirror plate 113 (depending upon whether substrate111 is light transmissive or not) would also generally be provided ifthe hinge is not formed in the same layer as the mirror plate.

As can be seen in FIG. 16B, light-absorbing layer 114 is directionallyetched removing almost all of the light-absorbing layer except forstrips of light absorbing material 114 a and 114 b along sides of themirror plate 113. Once the sacrificial layer 112 is removed as shown inFIG. 16C, a hinged reflective micro-mirror element having non-reflectivelight absorbing edges is formed, pivotably suspended above substrate111. As with the light absorbing matrices, the light absorbing mirroredges are preferably dark colored, preferably black. Also, though thelight absorbing mirror edges can be formed with deposition followed bydirectional etching as mentioned above, use of photoresist toselectively deposit the light absorbing material only around the edgesof the micro-mirror (or along the edges and “backside” of themicro-mirror), or using photoresist for etching the light absorbinglayer, can be performed. Many different combinations of materials anddeposition and patterning methods can be employed.

In addition to the edges or sidewalls of the micro-mirror, the peripheryof the reflective surface proximate to the edges or sidewalls can alsobe coated with light absorbing materials, as shown in FIG. 16D. In thisway, scattered light from defects and/or roughness near the edges maythus be reduced, if not eliminated.

In many operations, the backside surface opposite to the reflectivesurface for reflecting incident light can also increase scattered light,which scattered light can be collected by the projection lens or lensesof the projection system, thus reducing the contrast ratio. To eliminatethis scattered light, the backside surface of the micro-mirror can thenbe covered with a light-absorbing layer, for example, layer 114C in FIG.16E. It is also possible to cover the periphery of the micromirrorsurface, the edges or sidewalls and/or the underside of the micromirror,such as can be seen in FIG. 16F.

Whether for a situation when the micro-mirror plate and the backplanewafer with electrodes and control circuitry built thereon are separate,or whether for a situation where the control circuitry, electrodes andmicromirrors are formed on the same substrate, light-absorbing materialscan be deposited on the backplane to reduce the scattered light from thebackplane, as shown in FIGS. 18A and 18B. Referring to FIG. 18A,electrodes 63 can be covered with light-absorbing materials 67. FIG. 18Billustrates that all electrodes are covered with light-absorbingmaterial 67, however, this is not necessary. Instead, this substrate canbe selectively covered with the light-absorbing material as appropriate.

Whether for a situation when the micro-mirror plate and the backplanewafer with electrodes and control circuitry built thereon are separate,or whether for a situation where the control circuitry, electrodes andmicromirrors are formed on the same substrate, light-absorbing materialscan be deposited on the backplane to reduce the scattered light from thebackplane, as shown in FIGS. 18A and 18B. Referring to FIG. 18A,electrodes 63 can be covered with light-absorbing materials 67. FIG. 18Billustrates that all electrodes are covered with light-absorbingmaterial 67, however, this is not an absolute requirement. Instead,electrodes can be selectively covered with the light-absorbing materialas appropriate. It is also possible to form the electrodes themselvesfrom light absorbing material.

Alternatively, light-absorbing strips 68 can be deposited in the spacesbetween adjacent electrodes 63, as shown in FIG. 18B. The scatteredlight from these spaces can thus be reduced, if not eliminated. As anoptional feature, electrodes and the spaces between adjacent electrodescan be selectively covered with light-absorbing materials eitherindividually or in combination as appropriate (not shown). In oneembodiment, the electrodes are made of a light absorbing metal or metalalloy—or are covered with a light absorbing electrically conductivematerial, whereas the spaces in between the electrodes are filled with alight absorbing material that is electrically non-conductive. In anotherembodiment, the electrodes are covered with a light absorbingelectrically non-conductive material, whereas the spaces in between theelectrodes are filled with a light absorbing material that iselectrically conductive or non-conductive.

In a still further embodiment, a non-conductive (or mildly “leaky”)light absorbing material is deposited to cover the entire substrate ormost of the substrate. If the passivation layer is to be applied as acontinuous film over the electrode surface, it should preferablyeffectively act as an insulator at the frequencies of interest.Specifically the dielectric relaxation time of the material shouldpreferably be on the order of 1 s to 1 day. If the dielectric relaxationtime were lower, <1 sec, the film would act as a conductor andelectrostatically shield the mirrors from the influence of theelectrodes. If the dielectric relaxation time is higher, the mobilecharges in the material will react too slowly to mitigate any chargemigration or trapping. Dielectric relaxation time=(Absolute dielectricconstant)/(volume conductivity). Assuming the light absorbing materialof interest has a relative dielectric constant of about 5, then Volumeconductivity=4e-11/ohm-m or Volume resistivity=2.5e10 ohm-m=2.5e12ohm-cm. Assuming a film thickness of 1 um, the leakage resistancebetween neighboring pixels would be about 2.5e15 ohms. Thinner lightabsorbing films would also be desirable. Regardless of the type of film(CVD or sputtered thin film (e.g. SiC), spin on polymer (e.g.fluorinated or non-fluorinated dark or black colored polymer having theresistivity in the range as above) or hybrid organic-inorganic material(e.g. a fluorinated or non-fluorinated black or dark colored siloxanehaving the resistivity in the range as above), it is preferred that ithave a resistivity of from 2.5e12 ohm-cm to 1e15 ohm-cm. If the materialis deposited to cover the I/O pads (photoresist could be used to blockSiC deposition on the I/O pads for example), it should preferably beremoved after depositing.

Preferably, the light transmissive substrate bonded to the semiconductorsubstrate (or other substrate having circuitry and electrodes thereon)hermetically seals the MEMS elements from the surrounding environment,and preferably at a pressure lower than the surrounding environment. Inorder to achieve the lower pressure, the two substrates (dies or wafers)are bonded together at subatmospheric pressure and hermetically sealed(followed by wafer singulation if performed at the wafer level). Or, thetwo substrates could be bonded at ambient pressure, though nothermetically, followed by a second seal at a lower pressure thathermetically seals off the interior of the bonded substrates from thesurrounding environment. In one example of such a method, the twosubstrates are first bonded with an adhesive (e.g. epoxy or silicone)followed by soldering (this can be application of a solder or solderreflow) or other hermetic seal (e.g. glass frit seal) if the adhesive isinsufficiently hermetic. It is also possible to perform both seals atsubatmospheric pressure, or perform such a double seal at ambientpressure if it is not desired to have a lower pressure within the areabetween the two substrates. In addition, it may be desirable, whether atlower pressure or not, to seal the two substrates with a gas other thanair, such as an inert gas or gases (nitrogen, helium, etc.), or moisturecan be added if an anti-stiction agent would better perform if somemoisture is present in the package. This packaging can also be desirablefor a monolithic MEMS device where both the circuitry and MEMS elementsare on the same substrate, as well as where the MEMS elements are formedon a substrate different from the circuitry.

If an anti-stiction agent is deposited on the MEMS elements afterrelease, but before bonding the substrates together, it may be desirableto protect the areas that will be required for bonding (e.g. if anadhesive is used—protecting those areas where the adhesive will beapplied), followed by application of the anti-stiction agent, in turnfollowed by removing the protecting agent or film, followed in turn byapplication of the bonding agent. Such a film could be applied in stripsor rings that correspond to the location of the later applied bondingagent, and could be a photoresist or an inorganic thin film applied byCVD or sputtering. In the alternative, the MEMS elements could bereleased, followed by application of an anti-stiction agent. Then, theapplied anti-stiction agent (e.g. a self assembled monolayer formed fromchlorosilane or alkoxysilane precursors) is removed in the areas wherethe bonding agent will be applied (in any pattern—though preferablycircumferentially around the micro-mirror array if the MEMS elements aremicro-mirrors in an array). Removal can be accomplished by laserablation (preferably focusing laser above the substrate), particle beam,application of a stripping chemical (e.g. acetone) or even mechanicalremoval (scoring with a hard or soft object or with a polishing wheel).

There are many alternatives to the method of the present invention. Inorder to bond the two wafers, epoxy can be applied to the one or both ofthe upper and lower wafers. In a preferred embodiment, epoxy is appliedto both the circumference of the wafer and completely or substantiallysurrounding each die/array on the wafer. Spacers can be mixed in theepoxy so as to cause a predetermined amount of separation between thewafers after bonding. Such spacers hold together the upper and lowerwafers in spaced-apart relation to each other. The spacers act to holdthe upper and lower wafers together and at the same time create a spacein which the movable mirror elements can move. Alternatively, the spacerlayer could comprise walls or protrusions that are micro-fabricated. Or,one or more wafers could be bonded between the upper and lower wafersand have portions removed (e.g. by etching) in areas corresponding toeach mirror array (thereby providing space for deflection of the movableelements in the array). The portions removed in such intermediate waferscould be removed prior to alignment and bonding between the upper andlower wafers, or, the wafer(s) could be etched once bonded to either theupper or lower wafer. If the spacers are micro-fabricated spacers, theycan be formed on the lower wafer, followed by the dispensing of anepoxy, polymer, or other adhesive (e.g. a multi-part epoxy, or a heat orUV-cured adhesive) adjacent to the micro-fabricated spacers. Theadhesive and spacers need not be co-located, but could be deposited indifferent areas on the lower substrate wafer. Alternative to glue, acompression bond material could be used that would allow for adhesion ofthe upper and lower wafers. Spacers micro-fabricated on the lower wafer(or the upper wafer) and could be made of polyimide, SU-8 photo-resist.

Instead of microfabrication, the spacers could be balls or rods of apredetermined size that are within the adhesive when the adhesive isplaced on the lower wafer. Spacers provided within the adhesive can bemade of glass or plastic, or even metal so long as the spacers do notinterfere with the electrostatic actuation of the movable element in theupper wafer. Regardless of the type of spacer and method for making andadhering the spacers to the wafers, the spacers are preferably from 1 to250 microns, the size in large part depending upon the size of themovable mirror elements and the desired angle of deflection. Whether themirror arrays are for a projection display device or for opticalswitching, the spacer size in the direction orthogonal to the plane ofthe upper and lower wafers is more preferably from 1 to 100 microns,with some applications benefiting from a size in the range of from 1 to20 microns, or even less than 10 microns.

Regardless of whether the micro-mirrors and circuitry are formed on thesame wafer or on different wafers, when the micro-mirrors are releasedby removal of the sacrificial layer, a sticking force reducing agent canbe applied to the micro-mirrors on the wafer to reduce adhesion forcesupon contact of the micro-mirrors with another layer or structure on thesame or opposing substrate. Though such adhesion reducing agents areknown, in the present invention the agent is preferably applied to thewafer before wafer bonding (or after wafer bonding but beforesingulation), rather than to the singularized die or package for thedie. Various adhesion reducing agents, including varioustrichlorosilanes, and other silanes and siloxanes as known in the artfor reducing stiction for micro electromechanical devices, as mentionedelsewhere herein.

Also, a getter or molecular scavenger can be applied to the wafer priorto wafer bonding as mentioned above. The getter can be a moisture,hydrogen, particle or other getter. The getter(s) is applied to thewafer around the released MEMS structures (or around, along or adjacentan array of such structures, e.g. in the case of a micro-mirror array),of course preferably not being in contact with the released structures.If a moisture getter is used, a metal oxide or zeolite can be thematerial utilized for absorbing and binding water (e.g. StayDry SD800,StayDry SD1000, StayDry HiCap2000—each from Cookson Electronics). Or, acombination getter could be used, such as a moisture and particle getter(StayDry GA2000-2) or a hydrogen and moisture getter (StayDry H2-3000).The getter can be applied to either wafer, and if adhesive bonding isthe bonding method, the getter can be applied adjacent the epoxy beadsor strips, preferably between the epoxy and the micro-mirrors, and canbe applied before or after application of the adhesive (preferablybefore any adhesive is applied to the wafer(s). In one embodiment, agetter (or getters if more than one type of getter is used) is providedin a trench or other cavity formed in either (or both) substrates. Forexample, a trench extending along one or more sides of a micro-mirrorarray (or around the entire periphery of the array) could be formedprior to depositing the sacrificial layer and thin films (or at the endbefore or after release of the micro-mirrors). Such a trench (or cavity)could be formed in a silicon substrate (e.g. with circuitry andelectrodes thereon if formed as the dual substrate approach set forthabove, or circuitry, electrodes and micro-mirrors thereon if formedmonolithically). Or such a trench or cavity for the getter(s) could beformed in the glass substrate. It is also possible to form a trench orcavity in both substrates with the same or different getters depositedtherein.

In the method of the invention, the first wafer is preferably glass,borosilicate, tempered glass, quartz or sapphire, or can be a lighttransmissive wafer of another material. The second wafer can be adielectric or semiconductor wafer, e.g. GaAs or silicon. As noted above,the first and second wafers are bonded together with an adhesive (thoughmetal or anodic bonding are also possible), depending upon the MEMSstructure and the type of micromachining.

The releasing can be performed by providing any suitable etchant,including an etchant selected from an interhalogen, a noble gasfluoride, a vapor phase acid, or a gas solvent. And, the releasing ispreferably followed by a stiction treatment (e.g. a silane, such as achlorosilane). Also, a getter can be applied to the wafer before orafter the adhesion reducing agent is applied, and before or after anadhesive is applied (if an adhesive bonding method is chosen).Preferably the time from releasing to bonding is less than 12 hours, andpreferably less than 6 hours.

Specific mirrors and methods for projection displays or opticalswitching could be used with the present invention, such as thosemirrors and methods set forth in U.S. Pat. No. 5,835,256 to Huibersissued Nov. 10, 1998; U.S. Pat. No. 6,046,840 to Huibers issued Apr. 4,2000; U.S. patent application Ser. No. 09/767,632 to True et al. filedJan. 22, 2001; Ser. No. 09/564,069 to Richards filed May 3, 2000; Ser.No. 09/617,149 to Huibers et al. filed Jul. 17, 2000; Ser. No.09/631,536 to Huibers et al. filed Aug. 3, 2000; Ser. No. 09/626,780 toHuibers filed Jul. 27, 2000; Ser No. 60/293,092 to Patel et al. filedMay 22, 2001; Ser. No. 09/637,479 to Huibers et al. filed Aug. 11, 2000;and Ser. No. 60/231,041 to Huibers filed Sep. 8, 2000. If the MEMSdevice is a mirror, the particular mirror shapes disclosed in U.S.patent application Ser. No. 09/732,445 to Ilkov et al. filed Dec. 7,2000 could be used. In addition, the sacrificial materials, and methodsfor removing them, could be those disclosed in U.S. patent applicationSer. No. 60/298,529 to Reid et al. filed Jun. 15, 2001. Lastly, assemblyand packaging of the MEMS device could be such as disclosed in U.S.patent application Ser. No. 60/276,222 filed Mar. 15, 2001. Each ofthese patents and applications is incorporated herein by reference.

The invention has been described in terms of specific embodiments.Nevertheless, persons familiar with the field will appreciate that manyvariations exist in light of the embodiments described herein.

1. A method for making a spatial light modulator, comprising: forming anarray of circuitry and electrodes on a first substrate; forming a lightabsorbing layer on the first substrate to reduce reflections from thecircuitry and/or electrodes on the substrate; forming an array ofdeflectable reflective elements on the first substrate or on a secondsubstrate; and wherein the light absorbing layer is formed of a materialthat absorbs at least 50% of the light incident thereon and has aresistivity of from 2.5e12 ohm-cm to 1e15 ohm-cm.
 2. The method of claim1, further comprising: positioning the first and second substratesproximate to each other.
 3. The method of claim 2, wherein the array ofdeflectable elements is formed on the second substrate, and wherein thepositioning of the first and second substrates proximate to each othercomprises bonding the first and second substrates together to form thesubstrate assembly followed by singulating the substrate assembly into aset of assembly dies, each of which comprises a plurality of deflectablereflective elements.
 4. The method of claim 3, wherein the deflectablereflective elements correspond to a plurality of pixels in a direct-viewor projection display.
 5. The method of claim 1, wherein the lightabsorbing layer is formed as a grid for decreasing the amount of lightthat enters gaps between the deflectable elements.
 6. The method ofclaim 5, wherein an additional light absorbing area is formed as arectangular frame on the second substrate surrounding the array ofdeflectable reflective elements.
 7. The method of claim 1, wherein thelight absorbing layer is formed as a grid on the second substrate fordecreasing light that enters gaps between adjacent deflectable elements,and as a block of rectangular frames on the second substrate, each framesurrounding an array of deflectable reflective elements.
 8. The methodof claim 5, further comprising: depositing the light absorbing layerprior to forming the array of deflectable reflective elements.
 9. Themethod of claim 6, further comprising: depositing the light absorbinglayer after forming the array of deflectable reflective elements. 10.The method of claim 1, wherein the light absorbing layer is black incolor.
 11. The method of claim 1, wherein the light absorbing layerabsorbs at least 50% of the light incident thereon.
 12. The method ofclaim 11, wherein the light absorbing layer absorbs at least 75% of thelight incident thereon.
 13. The method of claim 12, wherein the lightabsorbing layer absorbs at least 85% of the light incident thereon. 14.The method of claim 3, further comprising: forming a light absorbingmatrix layer on the second substrate so as to decrease the amount oflight entering gaps between adjacent deflectable elements.
 15. Themethod of claim 3, wherein the number of reflective elements in each dieis from 6,000 to about 6 million.
 16. The method of claim 1, wherein thesecond substrate is an optically transmissive substrate or a substratehaving one or more layers that when removed result in an opticallytransmissive substrate in areas other than in the area of the lightabsorbing layer.
 17. The method of claim 16, wherein the secondsubstrate is glass, borosilicate, tempered glass, quartz or sapphire.18. The method of claim 1, wherein the first substrate is a dielectricor semiconductor substrate.
 19. The method of claim 18, wherein thefirst substrate is a GaAs or silicon substrate.
 20. The method of claim1, wherein the second and first substrates are bonded together with anadhesive.
 21. The method of claim 20, wherein the adhesive is an epoxy.22. The method of claim 1, wherein the first substrate is a glass orquartz substrate.
 23. The method of claim 3, wherein the bonding of thesubstrates comprises the dispensing of a UV or thermal cure epoxy. 24.The method of claim 2, wherein the aligning comprises aligning eachdeflectable element on the second substrate with at least one electrodeon the first substrate.
 25. The method of claim 3, wherein thesingulation of the substrate assembly comprises sawing partially througheach substrate followed by breaking along the sawed lines.
 26. Themethod of claim 3, wherein the bonding comprises applying a sealant nearthe perimeter of each array on the substrate.
 27. The method of claim 1,wherein the plurality of deflectable elements are reflective mirrorelements and are formed on the first substrate which is a lighttransmissive substrate.
 28. The method of claim 1, wherein the pluralityof deflectable elements are formed on the first substrate.
 29. Themethod of claim 1, wherein the circuitry and plurality of electrodes areformed prior to forming the plurality of deflectable elements, whereinthe plurality of deflectable elements are formed above the plurality ofelectrodes on the first substrate.
 30. The method of claim 29, whereinthe deflectable elements are held by at least a post connected to thefirst substrate so that each deflectable element is pivotably held aboveone or more electrodes.
 31. The method of claim 3, wherein when thesubstrate assembly is singulated into substrate assembly dies, a lightabsorbing mask is disposed on a portion within each substrate assemblydie on the second substrate.
 32. The method of claim 1, wherein theplurality of deflectable elements are formed on the second substrate.33. The method of claim 32, wherein when the second and first substratesare aligned and bonded together, the deflectable elements on the secondsubstrate are each disposed proximate to a corresponding electrode onthe first substrate.
 34. The method of claim 1, wherein the deflectableelements are micromirrors having jagged or zig-zag edges.
 35. The methodof claim 1, wherein the light absorbing layer is black nickel or blackchrome.
 36. The method of claim 1, wherein the light absorbing layer isa black or dark colored metal or metal alloy.
 37. The method of claim 1,wherein the light absorbing layer is a carbon containing polymer. 38.The method of claim 1, wherein the light absorbing layer is deposited bysputtering.
 39. The method of claim 1, wherein the light absorbing layeris a carbon containing film.
 40. The method of claim 1, wherein thelight absorbing layer comprises a carbon compound.
 41. The method ofclaim 1, wherein the light blocking layer is a multilayer film.
 42. Themethod of claim 1, wherein the light transmissive substrate comprises ananti-reflection coating on a surface opposite to the surface having thelight blocking layer.
 43. The method of claim 1, wherein the lightblocking layer is a light blocking frame around each die area.
 44. Themethod of claim 1, wherein the light blocking layer is a light blockingframe surrounding each micromirror.
 45. The method of claim 1, whereinthe light blocking layer comprises a plurality of light blocking strips,each of which proximate to a gap between adjacent micromirrors.
 46. Themethod of claim 3, wherein the second substrate is bonded to the firstsubstrate at a distance of less than 10 microns from the firstsubstrate.
 47. A spatial light modulator, comprising: an array ofcircuitry and electrodes on a first substrate; a light absorbing layeron the first substrate to reduce reflections from the circuitry and/orelectrodes on the first substrate; an array of micromirrors on the firstsubstrate or on a second substrate; and wherein the light absorbinglayer is formed of a material that absorbs at least 50% of the lightincident thereon and has a resistivity of from 2.5e12 ohm-cm to 1e15ohm-cm.
 48. The spatial light modulator of claim 47, wherein themicromirrors correspond to a plurality of pixels in a direct-view orprojection display.
 49. The spatial light modulator of claim 47, whereinthe light absorbing layer is formed as a grid surrounding theelectrodes.
 50. The spatial light modulator of claim 47, wherein thelight absorbing layer is formed as a series of discrete light-absorbingareas on the electrodes.
 51. The spatial light modulator of claim 48,wherein the first substrate is bonded to a light transmissive substratein a substrate assembly.
 52. The spatial light modulator of claim 47,wherein the light absorbing layer is black in color.
 53. The spatiallight modulator of claim 47, wherein the light absorbing layer absorbsat least 50% of the light incident thereon.
 54. The spatial lightmodulator of claim 53, wherein the light absorbing layer absorbs atleast 75% of the light incident thereon.
 55. The spatial light modulatorof claim 54, wherein the light absorbing layer absorbs at least 85% ofthe light incident thereon.
 56. The spatial light modulator of claim 47,wherein the light absorbing layer covers substantially all of the firstsubstrate.
 57. The spatial light modulator of claim 47, wherein thenumber of micromirrors in the array is from 6,000 to about 6 million.58. The spatial light modulator of claim 47, wherein the secondsubstrate is an optically transmissive substrate.
 59. The spatial lightmodulator of claim 58, wherein the second substrate is glass,borosilicate, tempered glass, quartz or sapphire.
 60. The spatial lightmodulator of claim 47, wherein the second substrate is a glass or quartzsubstrate.
 61. The spatial light modulator of claim 47, wherein thefirst substrate is a dielectric or semiconductor substrate.
 62. Thespatial light modulator of claim 61, wherein the first substratecomprises GaAs or silicon.
 63. The spatial light modulator of claim 47,wherein the first and second substrates are bonded together with anadhesive.
 64. The spatial light modulator of claim 47, wherein thesecond substrate is a glass substrate.
 65. The spatial light modulatorof claim 47, wherein the micromirrors are held by at least a post on thesecond substrate that is optically transmissive.
 66. The spatial lightmodulator of claim 47, wherein the micromirrors are formed on the secondsubstrate.
 67. The spatial light modulator of claim 66, wherein thecircuitry and plurality of electrodes are disposed on the firstsubstrate, wherein the micromirrors are positioned above and spacedapart from the plurality of electrodes on the second substrate.
 68. Thespatial light modulator of claim 47, wherein the micromirrors are formedon the first substrate.
 69. The spatial light modulator of claim 47,wherein each micromirror has jagged or zig-zag edge.
 70. The spatiallight modulator of claim 47, further comprising a stiction reducingagent on one or both substrates.
 71. The spatial light modulator ofclaim 47, wherein the light absorbing layer comprises black nickel orblack chrome.
 72. The spatial light modulator of claim 47, wherein thelight absorbing layer comprises a black or dark colored metal or metalalloy.
 73. The spatial light modulator of claim 47, wherein the lightabsorbing layer is a carbon containing polymer.
 74. The spatial lightmodulator of claim 47, wherein the light absorbing layer is deposited bysputtering.
 75. The spatial light modulator of claim 47, wherein thelight absorbing layer is a carbon containing film.
 76. The spatial lightmodulator of claim 47, wherein the light absorbing layer comprises acarbon compound.
 77. The spatial light modulator of claim 47, whereinthe light absorbing layer is a multilayer film.
 78. The spatial lightmodulator of claim 47, further comprising a light absorbing frame aroundeach die area.
 79. The spatial light modulator of claim 47, wherein thelight absorbing layer comprises at least two different light absorbingmaterials.
 80. The spatial light modulator of claim 47, furthercomprising a set of light-absorbing strips proximate to gaps betweenadjacent micromirrors.
 81. The spatial light modulator of claim 78,further comprising a light-absorbing frame surrounding each micromirror.82. The spatial light modulator of claim 81, wherein the light absorbingframe surrounding each micromirror is on the same side of the secondsubstrate as the micromirrors.
 83. The spatial light modulator of claim81, wherein the light absorbing frame surrounding each die is on a sideof the second substrate opposite to the side on which the micromirrorsare formed.
 84. The spatial light modulator of claim 47, wherein thefirst substrate is bonded to the second substrate at a distance of lessthan 100 microns from the second substrate.
 85. The spatial lightmodulator of claim 84, wherein the first substrate is bonded to thesecond substrate at a distance of less than 10 microns from the secondsubstrate.
 86. The spatial light modulator of claim 47, wherein thelight absorbing layer covers the electrodes but not gaps between theelectrodes.
 87. A method for making a spatial light modulator,comprising: providing a first substrate; forming an array of circuitryand electrodes on the first substrate; forming a light absorbing layeron the first substrate from a material that absorbs at least 50% of thelight incident thereon and has a resistivity of from 2.5e12 ohm-cm to1e15 ohm-cm; and forming an array of deflectable reflective elements onthe first or on a second substrate; and if on the second substrate,bonding the first and second substrates together to form a substrateassembly.
 88. A method for making a spatial light modulator, comprising:providing a first substrate and a second substrate; forming a pluralityof electrodes each of which is associated with a circuitry of an arrayof circuitry on the second substrate; depositing a discrete lightabsorbing area on each of the electrodes to form coated electrodes;forming a plurality of deflectable reflective elements on the first orsecond substrate; and disposing the first and second substrates suchthat each deflectable reflective element is positioned proximate to acoated electrode such that the deflectable reflective element is capableof being electrostatically actuated by the coated electrode.
 89. Themethod of claim 88, wherein the deflectable reflective elements areformed on the first substrate.
 90. The method of claim 88, wherein thedeflectable reflective elements are formed on the second substrate. 91.The method of claim 88, wherein each deflectable reflective element isassociated with a plurality of coated electrodes, the plurality ofcoated electrodes capable of alternately actuating the associateddeflectable reflective element.
 92. The method of claim 88, wherein thediscrete light absorbing areas are electrically conductive.
 93. Themethod of claim 88, wherein each coated electrode is positioned next toa single deflectable reflective element.
 94. The method of claim 88,wherein the first and second substrates are bonded together.
 95. Thespatial light modulator of claim 47, wherein the light absorbing layerabsorbs at least 50% of the light incident thereon.
 96. The spatiallight modulator of claim 53, wherein the light absorbing layer absorbsat least 75% of the light incident thereon.
 97. The spatial lightmodulator of claim 54, wherein the light absorbing layer absorbs atleast 85% of the light incident thereon.
 98. The spatial light modulatorof claim 47, wherein the light absorbing layer comprises black nickel orblack chrome.
 99. The spatial light modulator of claim 47, wherein thelight absorbing layer comprises a black or dark colored metal or metalalloy.
 100. The spatial light modulator of claim 47, wherein the lightabsorbing layer is a carbon containing polymer.
 101. The spatial lightmodulator of claim 47, wherein the light absorbing layer is deposited bysputtering.
 102. The spatial light modulator of claim 47, wherein thelight absorbing layer is a carbon containing film.
 103. The spatiallight modulator of claim 47, wherein the light absorbing layer comprisesa carbon compound.
 104. A method for making a spatial light modulator,comprising: providing a substrate; forming a plurality of electrodeseach being associated with a circuitry of a plurality of circuitry onthe substrate; depositing a discrete light absorbing area on each of theelectrodes to form coated electrodes; and forming a plurality ofdeflectable reflective elements positioned above the coated electrodes.105. The method of claim 104, wherein the deflectable reflectiveelements are formed on the substrate.
 106. The method of claim 104,wherein the deflectable reflective elements are formed on a secondsubstrate positioned proximate to the substrate.
 107. The method ofclaim 104, wherein each deflectable reflective element is disposedproximate to a plurality of coated electrodes, the plurality of coatedelectrodes capable of alternately actuating the proximate deflectablereflective element.
 108. The method of claim 104, wherein the discretelight absorbing areas are electrically conductive.
 109. The method ofclaim 104, wherein each electrode is positioned next to a singledeflectable element.
 110. The spatial light modulator of claim 104,wherein the light absorbing layer absorbs at least 50% of the lightincident thereon.
 111. The spatial light modulator of claim 110, whereinthe light absorbing layer absorbs at least 75% of the light incidentthereon.
 112. The spatial light modulator of claim 111, wherein thelight absorbing layer absorbs at least 85% of the light incidentthereon.
 113. The spatial light modulator of claim 104, wherein thelight absorbing layer comprises black nickel or black chrome.
 114. Thespatial light modulator of claim 104, wherein the light absorbing layercomprises a black or dark colored metal or metal alloy.
 115. The spatiallight modulator of claim 104, wherein the light absorbing layer is acarbon containing polymer.
 116. The spatial light modulator of claim104, wherein the light absorbing layer is deposited by sputtering. 117.The spatial light modulator of claim 104, wherein the light absorbinglayer is a carbon containing film.
 118. The spatial light modulator ofclaim 104, wherein the light absorbing layer comprises a carboncompound.
 119. A method for making a spatial light modulator,comprising: providing a first substrate and a second substrate; forminga plurality of electrodes each being associated with a circuitry of aplurality of circuitry on the second substrate; depositing lightabsorbing material to surround the electrodes such that the lightabsorbing material partially covers the second substrate; forming aplurality of deflectable reflective elements on the first substrate; anddisposing the first and second substrates such that each deflectablereflective element is positioned proximate to an electrode such that thedeflectable reflective element is capable of being electrostaticallyactuated by the electrode.
 120. The method of claim 119, wherein thedeflectable reflective elements are formed on the first substrate. 121.The method of claim 119, wherein the deflectable reflective elements areformed on the second substrate.
 122. The method of claim 119, whereineach deflectable element is formed or positioned proximate to aplurality of coated electrodes, the plurality of coated electrodescapable of alternately actuating the deflectable element.
 123. Themethod of claim 119, wherein the discrete light absorbing areas areformed from electrically conductive material.
 124. The method of claim119, wherein the first and second substrates are bonded together. 125.The method of claim 119, wherein the step of disposing the first andsecond substrates comprises bonding the first and second substratestogether such that each coated electrode is positioned next to a singledeflectable element.
 126. A method for making a spatial light modulator,comprising: providing a substrate; forming a plurality of electrodeseach with associated circuitry on the substrate; depositing lightabsorbing material to surround the electrodes such that the lightabsorbing material partially covers the substrate; and forming aplurality of deflectable reflective elements positioned above the coatedelectrodes.
 127. A method for making a spatial light modulator,comprising: providing a substrate; forming a plurality of circuitry andelectrodes on the substrate; depositing and patterning a photoresist onthe substrate so as to provide areas with and without the photoresist onthe substrate; depositing a light absorbing material so as to fill theareas without photoresist with the light absorbing material; andremoving the photoresist so as to leave selected areas on the substratewith light absorbing material.
 128. The method of claim 126, furthercomprising depositing a sacrificial material on the substrate,depositing and patterning a micromechanical structural material on thesacrificial material to form micromirrors, and removing the sacrificialmaterial in order to release the micromirrors.
 129. The method of claim126, further comprising forming micromirrors on a second substrate andbonding the substrate and the second substrate together.
 130. The methodof claim 126, wherein the light absorbing material is electricallyconductive.
 131. The method of claim 127, wherein a single micromirrorelement is formed proximate to a plurality of electrodes.
 132. Themethod of claim 129, wherein a single micromirror element is formedproximate to one or more coated electrodes.
 133. The method of claim127, wherein the light absorbing material is selectively deposited bydepositing a photoresist, patterning the photoresist so as to removephotoresist in selected areas, depositing the light absorbing material,and removing remaining photoresist.
 134. A method for making a spatiallight modulator, comprising: forming an array of circuitry andelectrodes on a first substrate; forming a light absorbing layer on thefirst substrate to reduce reflections from the circuitry and/orelectrodes on the substrate; and forming an array of deflectablereflective elements on the first substrate or on a second substrate;wherein the light absorbing layer is formed of a thin film ceramic,wherein the thin film ceramic is deposited by chemical vapor depositionor physical vapor deposition.
 135. The method of claim 134, wherein thethin film ceramic is a carbon compound.
 136. The method of claim 134,wherein the thin film is a chromium compound.
 137. The method of claim135, wherein the carbon compound is CN, CAlN, TiCN, a-DLC, SiC, TiAlCNor WC.
 138. The method of claim 137, wherein the light absorbing layeris black.
 139. A spatial light modulator formed by the method of any ofclaim 1, 87, 88, 104, 119, 126, 127 or
 134. 140. A projection system,comprising: a light source; a spatial light modulator for reflecting abeam of light from the light source; and a plurality of projectionoptics for projecting light reflected off of the spatial light modulatoronto a target; wherein the spatial light modulator is formed by a methodof any of claim 1, 87, 88, 119, 126, 127 or 134.